Book Review: Dust Explosions in the Process Industries, 3rd Edition

Fires and dust explosions are common and costly in many industries.  In this book Eckhoff has organized a comprehensive overview of his practical knowledge of the origin, development, prevention and mitigation of dust explosions, an up to date evaluation of testing methods, design measures and safe operating techniques.

Included are the research and findings of many other scientists, creating a definitive reference guide for information on the causes, effects and alternatives available for dealing with this complex subject, providing an excellent resource on dust explosions. This book will serve as a foundational reference on the subject of dust explosions in the process industries.  Also provided is detailed information of all phases of the hazard and control of a dust explosion. An invaluable reference.

-Jeff Nichols

As a resource to our valuable clients and readers, we provide the book review below from our colleague PUJAN AGNIHOTRI.

Mr. Agnihotri is an Associate Member of Society of Fire Protection Engineers (SFPE) & Member of National Fire Protection Association (NFPA), and research associate for www.IndustrialFirePrevention.com


Book Review: Dust Explosions in the Process Industries, 3rd Edition                                                            

Published by: Gulf Professional Publishing, An Imprint of Elsevier Science
                                            
ISBN 0-7506-7602-7, Hardcover, 705 pages, 2003

Author: Rolf K. Eckhoff, Professor of Process Safety Technology, The University of Bergen, Norway.

One of the major challenge in the field of fire protection & life safety engineering in process industries is Dust Explosion. Dust explosions are common & costly for a wide range of industries such as food, pharmaceutical, paper & petrochemical. Thus it is important to emphasis on in depth study of dust explosion to avert any higher intensity disaster like Sugar Dust Explosion at Imperial Sugar Factory, Georgia, February 7, 2008. This publication provides great deal of knowledge for all audience, from layman to fire protection & life safety experts, keenly interested in learning more about the dust explosion. Author has done an excellent job in compiling, from various sources, a large volume of material relating to dust explosion.

This publication helps reader to gain theoretical & practical knowledge about the origin, development, prevention & mitigation of dust explosions. It is divided in nine chapters with nearly 750 pages with tables, graphs, derivations & illustrative figures, for thorough understanding about the subject: Dust Explosion. The author has used more than 300 references for each chapter of this book.  Eckhoff made some modifications in his third edition of book; mainly a chapter on design of electrical equipment used in areas containing combustible dust, re-organized final review chapter with nearly 400 new literature references from years 1997-2002 & broad distribution of sections from the original chapters one to seven.

First chapter is an overview about the origin, propagation, prevention, & mitigation of dust explosions. Author in this chapter discusses the nature of dust explosions, statistical records, importance of dust & dust cloud properties in explosion, methods involve in prevention & mitigation of dust explosion and their selection criteria. This chapter provides us basic understanding about dust explosions.

Second chapter describes the history of dust explosion accidents all over the world. The author discusses dust explosion in flour warehouse, silo plant,  fish meal factory, large storage facilities, linen textile plant, coal dust plant, silicon powder grinding plant, slurry explosive factory, aluminum powder production plant. He covers dust explosion accident events in United States, United Kingdom, Norway, Germany, Canada, China, Russia & Sweden, from years 1785 to 1989. Author provided references to reports of more recent accidents in Chapter 9. 

From chapter 3 the author starts exploring the different parameters affecting dust explosions.  In this chapter, he discusses the explosive concentration of dust cloud through reentrainment & redispersion of deposited dust in air. He gives us a detailed understanding about the forces & strength of dust particles in powder or dust deposits and effects of gaseous medium on dust particle flow. He ends this chapter by providing methods for generating experimental dust clouds for research purpose. 

Chapter 4 gives us information regarding flames movement in dust clouds. Author studies different parameters like burning velocities, flame thickness, quenching distances, rate of pressure rise (for closed vessel), explosible concentration, dimension of enclosure & temperatures for laminar, non- laminar & turbulent flame propagation of coal dust, organic dust, metal dust & miscellaneous dust particles, through various derivation.  At the end of the chapter, author emphasizes detonation propagation in dust clouds in air.

In chapter 5, the author discusses the ignition of dust clouds & dust deposits. He talks about the self heating & self ignition of dust deposits, and dust clouds ignition from different sources like electric spark, mechanical rubbing, grinding, or impact & hot surfaces. Important parameters like minimum ignition temperatures, minimum ignition energy or minimum electric spark ignition energy, activation energy, minimum self-ignition temperature, are discussed in detail in this chapter.

Chapter 6 describes information regarding the vent sizing required for dust explosions. Author provides vent sizing methods used in Europe & United States. Further he provided derivation for calculating vent area in accordance to L/D (effective length/ diameter of the vessel), Pred (maximum pressure development in vented deflagration), Pmax (expected maximum pressure in vented explosions). Chapter 7 deals with laboratory scale tests for different properties of dust.

Chapter 8 research & development on dust explosions from years 1997 to 2002 in Chapter 9 are added in this edition of book. Chapter 8 discusses electrical apparatus usage in combustible dust containing area. Classification of areas, details of electrical apparatus design criteria, prevention of dust from potential ignition sources, intrinsically safe electrical apparatus are the topics discussed in detail in chapter 8. Chapter 9 concentrates on research & development in dust explosion field throughout the globe, with references for major dust explosion accidents in history. 

Summarizing, I would recommend that this book is a key source of information for professionals dealing with combustible dust in their Industries.


-PUJAN AGNIHOTRI

Tennessee OSHA Offers Combustible Dust Training

TOSHA is planning the 2010 spring seminars

The Tennessee Occupational Safety and Health Administration has four upcoming combustible dust training courses in their Spring 2010 Seminar Schedule

• Kingsport 04/16/2010 N.E.C.C.
  
• Morristown 05/13/2010 TCCI
• Smyrna 05/27/2010 TCCI
• Jackson 06/10/2010 TCCI

TO REGISTER:
TCCI—(615) 256-5141, www.tnchamber.org
Northeast State Community College-N.E.C.C. —(423) 354-2570
* For TN Chamber of Commerce & Industry members, a lower price applies.

TOSHA Spring 2010 Seminar Schedule

It's the fires, stupid, Dust Explosion Precursors

Dust fire sends Elkhart plant employees into cold

It's the fires, stupid. Another combustible dust related fire, precursor to potential dust explosion. The NFPA Fire Analysis and Research Division report on U.S. STRUCTURE FIRES IN INDUSTRIAL AND MANUFACTURING PROPERTIES reported that annually 29% of the reported structure fires involved shop tools and industrial equipment. In 15% of fires, the leading area of origin was the process or manufacturing area or workroom. Additionally, leading items first ignited in 10% of fires was dust, fiber, lint, sawdust, or excelsior in industrial and manufacturing properties.

Stakeholder Comments OSHA Combustible Dust Rulemaking

Follow this link to the numerous stakeholder comments for the OSHA Advanced Notice of Proposed Rulemaking on the Regulations.Gov site Better yet, got to the "View by Docket Folder" tab and Sign up for Email alerts on the right side of the page.

Glass-Reinforced Plastic Production Process $90K OSHA Fine

OSHA's inspection found that combustible particulate solids, which were generated during trimming and repair operations, were not collected into an adequately designed dust collection system, were allowed to accumulate on machinery and surfaces, and were not adequately cleaned up to prevent such buildup.

via osha.gov

Housekeeping appears to be the major issue with this recent OSHA citation for combustible dust fire and explosion hazards at a Pawcatuck, Connecticut plant. Reviewing a MSDS sheet for glass-reinforced plastics (GRP) highlights that GRP is a compound based upon a mix of glass fibre in a polyester and styrene resin based mix.

The fire hazards of GRP arise when combustible dust from machining and fabrication operations of combustible particulate solids may be explosive if mixed with air in critical proportions in the presence of an ignition source. Additionally, during storage and handling the dust generated during normal manufacturing operations can represent both a health hazard and a fire hazard. Most importantly as the OSHA news release informs stakeholders to use dust control equipment at the point of generation in machining and sawing operations.

An often overlooked potential ignition source are powered industrial trucks where combustible dust mentioned in this news release was exposed to several potential ignition sources, including an LP gas-powered industrial truck. What class of forklift are you using at your facility? Is it rated for use in potentially explosive atmospheres? The recent status report on the OSHA Combustible Dust NEP emphasized that combustible dust citations for powered industrial trucks was the third most cited violation after hazardous communication and housekeeping violations.

The 5th Annual Industrial Fire, Safety, and Security Conference (IFSS) in Houston, Texas will be hosting a Full-Day Combustible Dust Workshop on February 2, 2010, which will provide information assisting stakeholders in addressing potential combustible dust ignition sources. During one segment of the workshop, guest speaker Robert Zuiderveld, General Manager of Business Development Americas from Pyroban Corp. will share with attendees specific information on the operation of powered industrial trucks in combustible dust. work environments. Information throughout the full day workshop will assist stakeholders in operating and maintaining a safe workplace in addition to achieving OSHA regulatory compliance.

Good housekeeping is a major issue at facilities with the generation of combustible dust from combustible particulate solids. Many facility managers and owners are not aware of the proper methods in cleaning up the dust. You just can't take a compressed air hose and start blowing down the area nor sweeping while unaware of the dust clouds that can be generated, which provide an explosive atmosphere similar to a flammable vapor cloud. Potential ignition sources in the process are inherent at many facilities. The safe and approved alternative is the use of an explosive-proof rated vacuum cleaner.

Guest speaker Bruce Gordon, Senior District Manager, from Nilfisk CFM will speak in the afternoon at the Combustible Dust workshop on "Proper Housekeeping and Explosion-Proof Vacuums Hazardous Locations" concerning good housekeeping that will minimize the likelihood of a combustible dust related fire or explosion in addition to achieving regulatory compliance. OSHA combustible dust citations are costly yet a catastrophic secondary dust explosion leveling the facility can be even more of problem. Do you know about the combustible dust hazards at your facility?

Resources
Glass-Reinforced Plastics (GRP)

Webinar - Combustible Dusts in Industrial Ventilation Systems - Jan. 27, 2010

the ACGIH^® Industrial Ventilation Committee is hosting this webinar aimed at educating the EH&S community on the importance of preparing for and preventing dust related incidents in industrial ventilation systems.

via acgih.org

Over 60% of combustible dust General Duty Clause citation examples in the recent OSHA status report on Combustible Dust National Emphasis Program were for industrial ventilation issues. Jonathan F. Hale, MS, founder and co-owner of Air System Corporation & Diagnostics and Marty Schloss, PE and General Manager, southeast operations, for KBD/Technic, Inc., a CECO Environmental Company will provide attendees to the webinar with strategies in dust control and ignition control in preventing combustible dust related fires and dust explosions in addition vital information in maintaining current and future regulatory compliance.

This webinar has been approved by the American Board of Industrial Hygiene (ABIH) for .42 ABIH (IH) Certification Maintenance (CM) Point (. This webinar qualifies for .15 BCSP (SP) Continuance of Certification (COC) Point for Certified Safety Professionals. Participants seeking CM and/or COC points must attend the live webinar or view the archive and submit a final exam and evaluation. Certificates of Completion will be issued in a timely manner after receipt and completion of these items.

Who Should Attend this Webinar?

* Industrial Hygienists
* Occupational and Environmental Health Professionals
* Safety Professionals
* Environmental Engineers
* Plant Managers

ACGIH® Members: $292.50 Nonmembers: $325.00
Test and Certificate of Completion Only:*** $25.00 per person

Potentially Explosive Atmospheres Global Requirements

DOWNLOAD Intertek WHITE PAPER:
"Potentially Explosive Atmospheres Requirements"

Complete the registration form with the link below to receive a free copy of Intertek's informative white paper, and learn more about the differences between North American and European rules.

via intertek-etlsemko.com

Excellent Intertek document that explains global classification systems of potentially explosive atmospheres such as flammable atmospheres of gases, mists, liquids, combustible dusts, and fibres. Describes important differences between the Zone (Europe and NEC505) and Division (NEC500) systems in hazardous (classified) locations?

Posted via web from ComDust

Industry Groups Responses to OSHA Rulemaking

National Cotton Council (NCC)-urges OSHA to "use caution" in regulating textile mills concerning combustible dust in factories.

National Solid Wastes Management Association (NSWMA) -September 2008, OSHA issued an advisory stating there was no history of combustible dust events at transfer stations, materials recovery facilities (MRFs) or landfills

Georgia Proposed Combustible Dust Regulation

via inscomm.state.ga.us

The Georgia Office of Insurance and Safety Fire Commissioner will be holding a 10:00 a.m hearing on the 7th Floor, West Tower, Floyd Building, 2 Martin Luther King, Jr. Drive in Atlanta, GA , Monday January 25, 2010 on a proposed combustible dust regulation.

Prior to the upcoming hearing Georgia adopted an emergency regulation last year, "Rules and Regulations for Loss Prevention Due to Combustible Dust Explosions and Fire"

The proposed regulation, solely relying on the national industries (NAICS) listed in the OSHA Combustible Dust NEP is a sure path to disaster. Over 50% of combustible dust incidents in 2008 occurred in national industries (NAICS) not listed in Appendix D-1/D-2 of the OSHA NEP . So what about industries that create combustible dust in specific industry groups that have experienced either frequent combustible dust incidents or combustible dust incidents with catastrophic consequences that the Georgia Office of Insurance and Safety Fire Commissioner failed to acknowledge with a history of incidents?

Additionally, there is no guidelines in the proposed regulation that MSDS's will provide employers and workers with the most current information needed to understand the hazards associated with combustible dusts, as well as appropriate protective measures to be taken.

Information such as physical data (melting point, boiling point, flash point, etc.) is fine. But it does not include ignition sensitivity such as minimum ignition temperature (MIT) and explosion severity of combustible dusts. Over 80% of incidents are combustible dust related fires. Facility owners/managers are not aware that they need an ignition control program to minimize probability of combustible dust related fires.

The NFPA Fire Analysis and Research Division recently published a report on U.S. Industrial and Manufacturing Property Structure Fires For example, U.S. fire departments responded to an estimated average of 10,500 structure fires in industrial and manufacturing properties per year in 2003-2006.

• 29% Structure fires involved shop tools and industrial equipment
• 15% process or manufacturing area -leading area of origin
• 10% Dust, fiber, lint, sawdust, or excelsior-Leading Items First Ignited

How can stakeholders implement layers of protection for combustible dust related fires when there is no knowledge of MIT? It is dismaying that MIT is not mentioned in the physical properties but instead flash point is.

Another weak link in the proposed regulation is no mention that contractors also need training, same as employees, on the fire and explosion hazards of combustible dust. Many combustible dust related fires over the past two years have occurred due to contractors providing the ignition source while conducting hot work.

Hopefully some of these important issues will be brought up amongst the business, labor, and government stakeholders at the Monday morning meeting.

Posted via web from ComDust